Polaris Sportsman 500 RSE 1996-2000 Workshop Service Repair Manual

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The Polaris Sportsman 500 RSE, produced from 1996 to 2000, represents a robust and versatile all-terrain vehicle designed for a wide range of utility and recreational applications. Known for its...

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Type: Atv

Vendor:

Sku: 156100

Tags: 1996 1997 1998 1999 2000 Agriculture Atv Commando Series Polaris Same Sportsman 500 RSE Tractors

Product variants

Description

The Polaris Sportsman 500 RSE, produced from 1996 to 2000, represents a robust and versatile all-terrain vehicle designed for a wide range of utility and recreational applications. Known for its reliable 499cc liquid-cooled engine, automatic variable transmission, and the innovative On-Demand True All-Wheel Drive (AWD) system, the Sportsman 500 RSE offers excellent capability and traction in challenging terrain. Its sturdy construction, ample rack capacity, and substantial towing capacity make it a dependable workhorse for tasks such as farming, hunting, and trail maintenance, while also providing an enjoyable riding experience for outdoor enthusiasts. This comprehensive workshop service repair manual provides in-depth guidance for the maintenance, repair, and troubleshooting of your Polaris Sportsman 500 RSE. Covering all essential systems including the engine, drivetrain, suspension, brakes, and electrical system, this 503-page English-language guide is an indispensable resource. It features detailed, step-by-step instructions, diagnostic procedures, special tool references, wear limits, torque specifications, and clear safety precautions, all supported by detailed illustrations and diagrams. This manual is designed to empower both owners performing DIY maintenance and professional technicians to ensure the optimal performance and longevity of their vehicle.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Sportsman 500 RSE

Model Variant:

Model Years Covered:

1996, 1997, 1998, 1999, 2000

👋 Introduction

Market Position

Positioning:

Essential technical resource for owners and technicians of the Polaris Sportsman 500 RSE (1996-2000)

Competitive Analysis

Value Proposition:

Offers comprehensive, detailed repair and maintenance information for a specific model range, enabling cost-effective DIY repairs and efficient professional service.

Key Features

Download Speed:

Instant download post-payment for immediate access

Completeness:

100% complete and intact, no missing or corrupt pages/sections

Ease Of Use:

Simple explanations, easy-to-read reference for mechanics and DIY users

📋 Manual Details

Coverage Areas

Primary Coverage:

Repair, Maintenance, Troubleshooting, Service

Page Count

Total Pages:

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine:

Comprehensive engine overhaul, diagnostics, and repair

Drivetrain:

All-wheel-drive (AWD) system, transmission, differentials, CV joints

Suspension:

Front and rear suspension components, shocks, bushings, adjustments

Brakes:

Hydraulic brake system, calipers, master cylinder, fluid, bleeding procedures

Electrical System:

Wiring diagrams, ignition system, lighting, charging system, starter, battery

Fuel System:

Carburetor service and adjustment, fuel pump, fuel lines

Cooling System:

Radiator, fan, thermostat, coolant, hoses

Exhaust System:

Muffler, pipes, gaskets, mounting

Bodywork And Frame:

Body panel removal and installation, chassis components

Steering:

Steering mechanism, tie rods, steering wheel

Wheels And Tires:

Wheel mounting, tire pressures, lug nut torque specifications

Procedures Included

Maintenance:

Scheduled maintenance, fluid changes, filter replacements, lubrication

Troubleshooting:

Systematic diagnostic procedures for common and complex issues

Repair:

Step-by-step repair instructions for all major components

Disassembly Assembly:

Detailed instructions for removing and reinstalling parts

Adjustments:

Carburetor tuning, chain tension, cable adjustments

Diagnostics:

Testing procedures, electrical system diagnostics, component testing

Technical Depth

Depth:

Comprehensive, bumper-to-bumper coverage suitable for DIY and professional mechanics

Illustrations:

Detailed illustrations, exploded diagrams, drawings, and photos

Special Tools:

Reference to special service tool numbers and usage where applicable

Wear Limits:

Includes specific wear limits and tolerances for component replacement

Torque Specifications:

Detailed torque values for all critical fasteners

Safety Precautions:

Specific safety notes, cautions, and warnings (DANGER, CAUTION, NOTE)

📊 Manual Specifications

File Format

Format:

Searchable:

Likely searchable (typical for modern PDFs), though not explicitly stated

Print Quality

Printability:

Yes, all pages are printable

Resolution:

Assumed high enough for clear viewing and printing of diagrams

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

Compatibility

Operating Systems:

Windows, Mac, Linux OS

Software Requirement:

Adobe Reader

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, SOHC, 2-valve, 1-cylinder

Displacement:

499cc (30.4 cu. in.)

Bore X Stroke:

92mm x 75mm (3.62 x 2.95 in.)

Cooling System:

Liquid-cooled

Performance

Horsepower:

Approx. 30-33 hp (actual figures vary slightly by year)

Torque:

Approx. 28-30 lb-ft (actual figures vary slightly by year)

Fuel System

Carburetor:

Mikuni BSR42

Fuel Type:

Unleaded gasoline

Lubrication

Oil Type:

Refer to manual for specific viscosity and API classification (e.g., SAE 10W-40)

Oil Capacity:

Refer to manual for exact capacity (typically around 2.3 quarts/2.2 liters)

🔧 Transmission

Standard

Transmission Type:

Automatic (Polaris Variable Transmission - PVT)

Gear Selection:

High, Low, Neutral, Reverse, Park

Drive System:

On-Demand, True AWD (activated automatically when rear wheels lose traction)

Final Drive:

Shaft drive

Features

Belt Drive:

V-belt primary drive system

📐 Dimensions

Exterior

Length:

Approx. 83 inches (210.8 cm)

Width:

Approx. 46 inches (116.8 cm)

Height:

Approx. 47 inches (119.4 cm)

Weights

Dry Weight:

Approx. 640 lbs (290 kg)

Ground Clearance:

Approx. 11.25 inches (28.6 cm)

Wheelbase:

Approx. 50.5 inches (128.3 cm)

Towing Capacity:

1500 lbs (680 kg)

Rack Capacity Front:

250 lbs (113 kg)

Rack Capacity Rear:

400 lbs (181 kg)

🛡️ Safety Features

Ratings

Atv Safety Standards:

Manufactured to meet ANSI standards (specific safety ratings may not be directly applicable like automotive crash tests)

Active Features

Braking System:

Hydraulic disc brakes front and rear

Engine Braking:

Yes, inherent in the CVT system

Passive Features

Lighting:

Dual headlights, taillight/brake light

Operator Warnings:

Extensive use of NOTES, CAUTIONS, and WARNINGS within the manual for safe operation and repair

💡 Technology Features

Infotainment

Infotainment System:

N/A (This model is utility-focused and does not feature infotainment systems.)

Driver Assistance

Driver Assistance Features:

N/A (This model is utility-focused and does not feature driver assistance systems.)

Connectivity

Connectivity Features:

N/A (This model is utility-focused and does not feature connectivity features.)

🔧 Maintenance

Service Intervals

Oil Change Interval:

Refer to manual for specific intervals based on operating hours or mileage (e.g., every 100 hours or annually)

Air Filter Cleaning:

Regular inspection and cleaning/replacement as per manual recommendations

Spark Plug Replacement:

Refer to manual for recommended interval

Belt Inspection Replacement:

Crucial to inspect CVT belt for wear and damage at regular intervals, replace as needed

Fluid Specifications

Engine Oil:

SAE 10W-40, API SG or higher (verify in manual)

Coolant:

Ethylene glycol-based coolant, typically a 50/50 mix with distilled water (verify in manual)

Gearcase Oil:

Refer to manual for specific gear oil specification (e.g., SAE 80W-90 GL-5)

Brake Fluid:

DOT 3 or DOT 4 brake fluid (verify in manual)

Known Issues

Cv Joint Boots:

Wear and tear on CV joint boots can lead to contamination and premature failure of the joint.

Carburetor Issues:

Carburetors can be prone to clogging or needing adjustment over time, especially with inconsistent fuel usage or storage.

Electrical Connections:

Corrosion or looseness in electrical connectors can cause intermittent faults.

Suspension Bushings:

Wear in suspension bushings can lead to a loose feel and premature wear on other components.

Radiator Fan:

The electric radiator fan can sometimes fail or have wiring issues.

📚 Vehicle History

Brand Heritage

Brand Focus:

Polaris is a well-established manufacturer of powersports vehicles, including ATVs, snowmobiles, and motorcycles.

Model Evolution

Sportsman Line:

The Sportsman line has been a cornerstone of Polaris' ATV offerings, known for its comfort, utility, and capable AWD system.

500Cc Engine:

The 500cc engine was a popular and robust powerplant for Polaris during this era, offering a good balance of power and reliability.

Production

Manufacturing Location:

Primarily manufactured by Polaris Industries in the USA.

🏆 Awards & Recognition

Recognitions

Industry Awards:

While specific awards for this exact model year are not readily available in general descriptions, the Polaris Sportsman line has consistently received positive reviews and recognition for its performance and innovation in the ATV market.